US5189781A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Rapid tool manufacturing
Assignee: Carnegie Mellon University
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Filing: 1992-01-10
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Granted: 1993-03-02
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Expires: 2012-01-10
Abstract
Abstract A method for rapid tool manufacturing comprising the steps of first building an SFF pattern made of plastic to be used to make a first die half. Then there is the step of spraying metal onto the pattern to form a first metal substrate. Next, there is the step of separating the substrate from the SFF pattern to form the first die half. Then there is the step of building a second SFF pattern to be used to make a second die half. Next, there is the step of spraying metal onto the second SFF pattern to form a second metal substrate. Then there is the step of separating the second metal substrate from the second SFF pattern to form the second die half. In a preferred embodiment, the method for rapid tool manufacturing the second die half is formed by first the step of building an SFF model of a part to be molded. Then, there is the step of inserting the model into the first die half. Next, there is the step of spraying metal onto the model in the first die half to form a second metal substrate. Then there is the step of separating the second metal substrate from the model and the first die half to form the second die half.
Inventors
- 👤 Lee E. Weiss
- 👤 Friedrich B. Prinz
- 👤 E. L. Gursoz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 21:07
CPC Classifications
C; C23; C23C; C23C4/00; C23C4/18; C23C4/185; B; B23; B23P; B23P15/00; B23P15/02; B23P15/24; B29; B29C; B29C64/00; B29C64/10; B29C64/106; B29C64/124; B29C64/129; B29C64/135; B33; B33Y; B33Y10/00; B33Y80/00; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/4998; Y10T29/49982
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
104 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a first die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a first metal substrate; separating the substrate from the SFF pattern to form the first die half; building a second SFF pattern to be used to make a second die half; spraying metal onto the second SFF pattern to form a second metal substrate; and separating the second metal substrate from the second SFF pattern to form the second die half.
Claim 2
Independent Claim
104 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a first die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a first metal substrate; separating the substrate from the SFF pattern to form the first die half; building a second SFF pattern to be used to make a second die half; spraying metal onto the second SFF pattern to form a second metal substrate; and separating the second metal substrate from the second SFF pattern to form the second die half.
Claim 3
Independent Claim
114 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a first die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a first metal substrate; separating the substrate from the SFF pattern to form the first die half; building an SFF model of a part to be molded; inserting the model into the first die half; spraying metal onto the model in the first die half to form a second metal substrate; and separating the second metal substrate from the model and the first die half to form the second die half.
Claim 4
Independent Claim
114 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a first die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a first metal substrate; separating the substrate from the SFF pattern to form the first die half; building an SFF model of a part to be molded; inserting the model into the first die half; spraying metal onto the model in the first die half to form a second metal substrate; and separating the second metal substrate from the model and the first die half to form the second die half.
Claim 5
Dependent Claim
31 words
A method as described in claim 2 including after the step of spraying metal onto the pattern the step of pouring backing material onto the first metal substrate to support it.
Claim 6
Dependent Claim
29 words
A method as described in claim 3 including before the step of spraying metal on the pattern, the step of applying a water soluble release agent on the pattern.
Claim 7
Dependent Claim
26 words
A method as described in claim 4 wherein the step of separating the substrate from the pattern includes the step of dissolving the water-soluble release agent.
Claim 8
Dependent Claim
50 words
A method as described in claim 5 including after the step of building the SFF pattern, the step of placing a metal frame onto the pattern; and wherein the step of spraying metal on the pattern includes the step of spraying metal around the inside edge of the metal frame.
Claim 9
Dependent Claim
26 words
A method as described in claim 6 including before the pouring step the step of laying in place on the first metal substrate tubing for channels.
Claim 10
Dependent Claim
91 words
A method as described in claim 7 including after the inserting step, the step of applying a water-soluble release agent on the model, and placing a second metal frame on the first die half; and after the step of spraying metal onto the model and around the inside edge of the frame; the steps of laying in place on the model tubing for cooling channels; pouring backing material on the model to support the second metal substrate; and dissolving the water-soluble release agent between the second metal substrate and the model.
Claim 11
Dependent Claim
19 words
A method as described in claim 8 wherein the building step includes the step of building an SLA pattern.
Claim 12
Dependent Claim
33 words
A method as described in claim 1 wherein the spraying step includes the step of spraying metal onto the pattern in multiple layers without any solid layer between the pattern and the metal.
Claim 13
Dependent Claim
34 words
A method as described in claim 10 wherein the step of building any SFF pattern made of plastic includes the step of building an SFF pattern made of plastic from a computer-based geometric model.
Claim 14
Dependent Claim
28 words
A method as described in claim 11 wherein the spraying step includes the step of robotically spraying metal onto the pattern in correspondence with the computer-based geometric model.
Claim 15
Dependent Claim
25 words
A method as described in claim 12 wherein before the building step, there is the step of creating the computer-based model on a CAD/CAM system.
Claim 16
Dependent Claim
17 words
A method as described in claim 13 wherein the spraying step includes the step of spraying zinc.
Claim 17
Dependent Claim
33 words
A method as described in claim 2 wherein the spraying step includes the step of spraying metal onto the pattern in multiple layers without any solid layer between the pattern and the metal.
Claim 18
Dependent Claim
34 words
A method as described in claim 15 wherein the step of building an SFF pattern made of plastic includes the step of building an SFF pattern made of plastic from a computer-based geometric model.
Claim 19
Dependent Claim
21 words
A method as described in claim 16 wherein the spraying step includes the step of robotically spraying metal onto the pattern.
Claim 20
Dependent Claim
25 words
A method as described in claim 17 wherein before the building step, there is the step of creating the computer-based model on a CAD/CAM system.
Claim 21
Dependent Claim
17 words
A method as described in claim 18 wherein the spraying step includes the step of spraying zinc.
Claim 22
Independent Claim
57 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a metal substrate; separating the substrate from the SFF pattern to form the die half.
Claim 23
Independent Claim
57 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern made of plastic to be used to make a die half; spraying metal onto the pattern without any solid layer between the pattern and the metal to form a metal substrate; separating the substrate from the SFF pattern to form the die half.
Claim 24
Dependent Claim
33 words
A method as described in claim 20 wherein the spraying step includes the step of spraying metal onto the pattern in multiple layers without any solid layer between the pattern and the metal.
Claim 25
Dependent Claim
34 words
A method as described in claim 21 wherein the step of building an SFF pattern made of plastic includes the step of building an SFF pattern made of plastic from a computer-based geometric model.
Claim 26
Dependent Claim
21 words
A method as described in claim 22 wherein the spraying step includes the step of robotically spraying metal onto the pattern.
Claim 27
Dependent Claim
25 words
A method as described in claim 23 wherein before the building step, there is the step of creating the computer-base model on a CAD/CAM system.
Claim 28
Dependent Claim
17 words
A method as described in claim 24 wherein the spraying step includes the step of spraying zinc.
Claim 29
Independent Claim
35 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern from a computer-based geometric model; and robotically spraying metal onto the SFF pattern in correspondence with the computer based geometric model.
Claim 30
Independent Claim
35 words
A method for rapid tool manufacturing comprising the steps of: building an SFF pattern from a computer-based geometric model; and robotically spraying metal onto the SFF pattern in correspondence with the computer based geometric model.
Claim 31
Dependent Claim
26 words
A method as described in claim 26 wherein before the building step, there is the step of creating the computer-based geometric model on a CAD/CAM system.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-03-01 | 1996-08-31 | 1997-03-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-03-01 | 2000-08-31 | 2001-03-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-03-01 | 2004-08-31 | 2005-03-02 | $7700.00 | Window Closed / Lapsed |